Turbine designers are finding new ways to lower costs, increase efficiency and capacity, minimize maintenance requirements, and reduce the size and weight of the equipment. Recent developments are delivering business benefits, particularly in the renewables space.
Sheila Kennedy is a professional freelance writer specializing in industrial and technical topics. She established Additive Communications in 2003 to serve software, technology, and service providers in industries such as manufacturing and utilities, and became a contributing editor and Technology Toolbox columnist for Plant Services in 2004. Prior to Additive Communications, she had 11 years of experience implementing industrial information systems. Kennedy earned her B.S. at…

The keys to success for a CM analyst are many and vary somewhat from individual to individual.

Being a successful condition monitoring (CM) analyst requires qualities such as intelligence, dedication, a thick skin, willingness to help others, ability to focus, and more. Success in this profession is not easy. In fact, it can be argued that…

The keys to success for a CM analyst are many and vary somewhat from individual to individual.

Being a successful condition monitoring (CM) analyst requires qualities such as intelligence, dedication, a thick skin, willingness to help others, ability to focus, and more. Success in this profession is not easy. In fact, it can be argued that…

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The keys to success for a CM analyst are many and vary somewhat from individual to individual.

Being a successful condition monitoring (CM) analyst requires qualities such as intelligence, dedication, a thick skin, willingness to help others, ability to focus, and more. Success in this profession is not easy. In fact, it can be argued that…

The keys to success for a CM analyst are many and vary somewhat from individual to individual.

Being a successful condition monitoring (CM) analyst requires qualities such as intelligence, dedication, a thick skin, willingness to help others, ability to focus, and more. Success in this profession is not easy. In fact, it can be argued that…

Preventive maintenance is a predetermined task performed based on a schedule and its objective is to keep equipment in good condition to avoid breakdowns. With properly scheduled monitoring and data collection, this testing can be very useful in…

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Effective lubrication and contamination protection help to maintain bearing strength and capacity.

The battle against corrosion is challenging, and some industries are more sensitive to it than others. Avoidance and prevention are particularly important in food, beverage, and medical processing applications where damage from corrosive invasion is costly. Corrosion is damaging from a wide variety of perspectives. It weakens base materials, limits machine longevity, is cosmetically unappealing, can create resulting impurities, and can ultimately impact production. Many manufacturers of power transmission products are continually researching methods and means to win this battle.
Mounted bearing product offerings have changed considerably in the past 15 years. Many bearing manufacturers have listened to their customers’ needs and have…

Plant Services/ARC Advisory Group joint survey reveals how technologies are being used.

How is PdM being implemented in the average plant today? In a joint survey conducted by Plant Services and ARC Advisory Group, maintenance and reliability professionals shared their experiences and insights into the day-to-day use of PdM on the plant floor.
Many plants are ahead of the curve and already have some form of predictive maintenance implemented in their facilities. Quite a few are using vibration analysis and infrared imaging, as well as oil analysis and electric motor testing. However, predictive modeling software and acoustic technology were not even on the radar for the 90 survey participants (Figure 1).
Figure 1. Quite a few plants are using vibration analysis and infrared imaging, as well as oil analysis and electric…

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Sheila Kennedy examines maintenance from a distance.

The most efficient and cost-effective predictive maintenance (PdM) programs are able to remotely access asset condition data and draw it into the cloud for analysis. These capabilities are increasingly being leveraged in both internal, outsourced, and OEM-based PdM programs to enhance their success.
Analysis enablers
Implementing predictive maintenance can be cost prohibitive for small and mid-sized businesses. With the Machine Health Reporting Program (MHRP) from SKF, the equipment and training investments are avoided. Instead, vibration data collected during normal maintenance is sent to a cloud server and remotely analyzed by SKF reliability engineers.
“MHRP creates a partnership between SKF and the client to determine the root…

Chinese machine production is expected to increase again this year — by 7.4%. Interestingly, that’s a slowdown in expansion, from 7.9% growth in 2013, according to the quarterly tracker for Chinese Machinery Production from IHS.
When I wrote about China’s equipment-manufacturing growth almost five years ago (www.plantservices.com/china1 and www.plantservices.com/china2), researchers were predicting that machine-building behind the Great Wall would surpass that of any other country by 2011. As we head down the homestretch of 2014, China has now set its sights on building and hosting the world’s largest machine. The reigning goliath, CERN’s Large Hadron Collider (LHC) near Geneva, Switzerland, fired its first protons on Sept. 19,…

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How to avoid paralysis through analysis.

Performance evaluation of rotating machinery in a refinery can provide many benefits to the plant engineering and reliability team. This case study deals with pumps; however, such an exercise can be applied equally to other major and critical pieces of machinery available in an operating plant. Centrifugal compressor monitoring can be done using such an approach to evaluate the operating context of the compressor. Variables such as the operating margin around the anti-surge line, compressor polytropic head and efficiency, and gas horsepower can be readily determined in real time giving valuable information on the condition of a particular asset. This approach also helps in cutting back heavy reliance on the OEM and utilizing on-site,…

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Remote control and monitoring innovations are driving greater productivity, efficiency, and safety on crane systems.

Cranes are critical in a number of industries, including aircraft/aerospace, auto manufacturing, chemicals and minerals, pulp and paper, steel production, and utilities, as well as the grain industry, logging, rail yards, and ship loading.
Traditionally, industrial cranes have been operated by human operators sitting in cabs in the cranes. In such instances, the operator's actions are guided by the hand signals of a person outside of the crane. "In the past, cranes were operated by the cab operators," says Brad Robinson, president of Robinson Engineering, which has been offering remote control technologies since 1962. "The guy on the ground was hooking the chains, doing the loading, and having to wave his hands to direct the operator where…

When a motor fails, weigh these factors to make the best choice.

When a motor fails, plant maintenance and engineering teams must decide between rewinding, repairing, or replacing the motor, and the best economic decision for a given asset is not always clear. What factors do industry practitioners evaluate in order to make a well-informed decision on repairing versus replacing?
“Motors fail for many reasons other than age or hours of operation,” says Mark Burgess, General Product Manager, Specialty & Definite Purpose Motors, Baldor Electric. “When a motor does fail, two things to consider are cost to repair or replace and operator downtime.”
Before repairing an existing motor it is important to know the cost of repair compared to the cost of a new motor, says Burgess. “After the EPAct…

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Increase your ROI by making sure you can identify opportunities and properly document results.

Reliability centered maintenance is all about making sure plants are running their best. There are a number of benefits that can arise from this simple endeavor, including safety, machine performance, overhead savings and a smaller carbon footprint. Eliminating waste has become a priority for both industry professionals and national governments, as the private sector looks for new ways to increase revenues, while countries around the world are looking to cut back on carbon emissions. By fixing and controlling compressed air leaks, we can address both of these concerns.
There are a number of ways that companies can see strong returns on investment through fixing compressed air leaks. With concerns about carbon emissions growing, governments…

In this Big Picture Interview, John Martini explains what's new, what's now and what to consider before you invest.

John Martini is an assistant professor of electronics technology at the University of Arkansas - Fort Smith, where he teaches classes in the robotics certification program. His educational background includes an Associate of Applied Science in…

Thomas Wilk explores the common routes to market for 3DP products and services.

By now you may be familiar with a story from last December on how NASA “emailed” a wrench from Earth to the International Space Station. Specifically, NASA built a CAD file of the requested ratcheting socket wrench, converted it into a file…

Turbine designers are finding new ways to lower costs, increase efficiency and capacity, minimize maintenance requirements, and reduce the size and weight of the equipment. Recent developments are delivering business benefits, particularly in the renewables space.
Sheila Kennedy is a professional freelance writer specializing in industrial and technical topics. She established Additive Communications in 2003 to serve software, technology, and service providers in industries such as manufacturing and utilities, and became a contributing editor and Technology Toolbox columnist for Plant Services in 2004. Prior to Additive Communications, she had 11 years of experience implementing industrial information systems. Kennedy earned her B.S. at…

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Achieve continuous improvement while optimizing cost, risk, and performance across the asset lifecycle.

The discipline of physical asset management is rapidly evolving as companies rush to understand the market implications of this newly released standard on asset management. Each business has their own particular reasons, but they tend to all arrive…

3D facility and equipment modeling improves design visualization as well as plant maintenance and expansion tasks. The U.S. General Services Administration is requiring phased 3D, 4D, and building information modeling (BIM) adoption for major…

Sheila Kennedy examines maintenance from a distance.

The most efficient and cost-effective predictive maintenance (PdM) programs are able to remotely access asset condition data and draw it into the cloud for analysis. These capabilities are increasingly being leveraged in both internal, outsourced, and OEM-based PdM programs to enhance their success.
Analysis enablers
Implementing predictive maintenance can be cost prohibitive for small and mid-sized businesses. With the Machine Health Reporting Program (MHRP) from SKF, the equipment and training investments are avoided. Instead, vibration data collected during normal maintenance is sent to a cloud server and remotely analyzed by SKF reliability engineers.
“MHRP creates a partnership between SKF and the client to determine the root…

Preventive maintenance is a predetermined task performed based on a schedule and its objective is to keep equipment in good condition to avoid breakdowns. With properly scheduled monitoring and data collection, this testing can be very useful in…

Meeting the world’s energy needs in the 21st century looms as one of the most complex, overarching issues of our time.

Energy supply and demand: why is it such a divisive issue? The problem is that it is not just about individual consumption; oil and gas supply and demand is a central issue not only to the health of the global economy, but the global ecosystem as well. It’s not surprising that the rhetoric surrounding energy consumption often mentions the fate of the planet and the survival of humanity.
The United Nations (U.N.) has estimated that the world’s population would reach 7.2 billion by early 2014 and that 82 million people would be added each year, with 25 percent of this growth occurring in the least developed countries. At current rates, the total population of the planet will reach 8.1 billion in 2025 and 9.6 billion in 2050, according to…

Power is a critical resource to an industrial plant, so power problems require power solutions. Many industrial facilities have their own on-site power-generation capabilities to reduce energy costs and to compensate for the potential of short-term utility outages. Power quality can have different kinds of impact on operations and production. There are just as many causes of poor power quality as there are options to solve them, and many of them are extremely affordable.
Harmonic distortion
"Voltage imbalance is a huge issue with motors," says Dan Chamberlain, electrical PDG lead CCMNA for Cargill in Dayton, Ohio. "Allied Reliability Group has been working with all of Cargill's corn milling facilities for a number of years and always…

Turbine designers are finding new ways to lower costs, increase efficiency and capacity, minimize maintenance requirements, and reduce the size and weight of the equipment. Recent developments are delivering business benefits, particularly in the renewables space.
Sheila Kennedy is a professional freelance writer specializing in industrial and technical topics. She established Additive Communications in 2003 to serve software, technology, and service providers in industries such as manufacturing and utilities, and became a contributing editor and Technology Toolbox columnist for Plant Services in 2004. Prior to Additive Communications, she had 11 years of experience implementing industrial information systems. Kennedy earned her B.S. at…

This article discusses the advantages and limitations of each technology in various wastewater treatment applications.

Blower selection is an important decision when designing a new wastewater treatment plant or upgrading existing facilities. The proper selection of blower equipment for the application, as well as purchasing from a reputable supplier, can save thousands of dollars in energy, repairs and maintenance costs. This article provides an overview of the blower technologies available for wastewater treatment, and discusses the advantages and limitations of each technology in various wastewater treatment applications.
Take a look at a municipal wastewater treatment plant near a textile factory in Asia (Figure 1). Is there any question as to why we treat industrial wastewater? The use of blowers for aeration and mixing accounts for 40 to 75 percent…

In this installment of What Works, new fans and lights boost comfort and productivity.

When it set out to upgrade a 30,000 ft2 facility to house a custom injection molding plant, M3 Production had a problem on its hands: The original fluorescent lighting generated a lot of heat and very little light.
That didn’t cut it for M3 Production. The company’s operators need vivid light to examine small parts for cosmetic defects. In fact, some customers require a specific light level before agreeing to do business. Beyond that, M3 Production’s employees needed basic comfort, especially in the facility’s break area. And they needed a single company that could do it all, from a customized recommendation to installation.
After speaking with Danny Allen, vice president of operations at M3 Production, and a visit to the M3 plant…

In this Plant Profile, a sensor manufacturer increases global footprint in Kentucky.

The Balluff Florence facility manufactures linear transducers and encoders. Containing high-tech electronics, these devices are customized to each customer’s needs and require precision testing and assembly.
With the 2014 expansion of its campus in Florence, Kentucky, Balluff, the German sensor manufacturer and automation supplier, takes another significant step in improving its global production and logistics footprint.
Balluff ships more than 200,000 products through its existing 56,000-sq-ft Florence facility annually. The new space adds 48,000 sq ft, as well as more jobs and increased production.
“By 2016 production hours in the Kentucky facility will increase 140%,” says Florian Hermle, global managing director and owner.

Lean strategies harvest the low-hanging fruit of maintenance savings.

Lean processes, while being widely deployed in manufacturing, are only now gaining the recognition they deserve in plant and facilities maintenance. Regardless of the systems in place, the visibility and management of critical spares and MRO procurement represents in many cases the low-hanging fruit and most easily accessible savings opportunities.
More Visibility + More Information = Better Decisions
Employees thrive on information. Tablets and easy access to computers or workstations provide the opportunity to empower employees like never before. Technicians can receive notifications that work orders are pending, access and interact with work orders on mobile devices, view manuals, diagrams schematics and images all at point-of-use and…

David Berger outlines an approach to more successfully manage change, including relevant features available from today’s more advanced CMMS packages.

One of the most costly issues faced by asset managers today is the inability to effectively manage changes relevant to their equipment, processes, information systems and people. For example, if an unexpected failure occurs and a quick fix solution is implemented, does anyone properly follow up with an investigation, risk assessment, and cost/benefit analysis of more permanent alternative solutions, instead of a patchwork of bandaid solutions? Is there proper documentation and an audit trail recording these steps, including version control on all documents? This column outlines an approach to more successfully manage change, including relevant features available from today’s more advanced CMMS packages.
Some definitions
Management of…

In this Big Picture Interview, Robert Perez explores the role of the machinery reliability engineer.

Robert X. Perez is a machinery reliability engineer with more than 30 years of experience in the petrochemical industry. He earned a BSME degree from Texas A&M University, College Station, and an MSME degree from the University of Texas at Austin, and he’s a licensed professional engineer in the state of Texas. He has written extensively about machinery reliability and served on the Turbomachinery Symposium Advisory Committee for 10 years.
PS: What does a machinery reliability engineer do?
RP: A machinery reliability engineer, or MRE, is a subject matter expert in the field of process machinery, such as centrifugal compressors, centrifugal pumps, reciprocating compressors, reciprocating pumps, and steam turbines. As an MRE my job…

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These pointers can help industrial plant managers select a contractor for outsourcing maintenance and reliability services.

At some point in time every industrial plant must bring in an outside contractor to do specialized work such as boiler blasting, concrete waterproofing and ceiling painting that in-house manpower can’t perform on a cost-effective basis. Such an option makes sense, in that many industrial operations don’t enjoy the luxury of reassigning staff to do labor-intensive work that requires additional training. Nor does facility management have at their ready disposal the unique equipment required to perform major maintenance or upgrade projects.
However, the greater challenge lies not in deciding whether to call in outside help, but, rather, determining which contractor is best able to perform the job on time, within budget, with the best…

One of the biggest mistakes a company can make in thinking about cybersecurity is thinking of it strictly as a technology concern, a Department of Homeland Security official told ARC Forum attendees Tuesday.
"Many of you folks previously thought cybersecurity was all about technology," said Gregory Touhill, deputy assistant secretary of cybersecurity operations and programs at the DHS and a retired brigadier general. "I'm here to tell you cybersecurity is not a technology issue; it's a risk-management issue."
As such, companies need to ensure cybersecurity isn't relegated to IT-specific discussions but rather is a staple of meeting agendas and a factor in all decisions made that address business risks.
"Do you know how much your…

Workplace electrical safety has evolved in the United States and Canada with the application of NFPA 70E, the U.S. standard for electrical safety in the workplace, and CSA Z462, Canada’s workplace electrical safety standard published on Dec. 28, 2008. With CSA Z462 now in its published second edition and the third edition in the works, energized electrical work in Canada will never be the same. But is this enough? Have we missed a key variable in electrical safety? What about electrical equipment maintenance?
There are really three key elements to electrical safety and ensuring that risk related to energized electrical power systems is reduced to as low as reasonably practicable (ALARP): safe installations, safe work practices, and…

What’s revised, why, and how much it will cost.

This is the second of a two-part update on OSHA’s new rules on electric power generation, transmission, and distribution. This part looks at what’s revised, why, and the cost. Read part one of this article, Are new OSHA rules on electrical safety regular or supersize?When the U.S. Occupational Safety and Health Administration (OSHA) released its changes to rules that affect electric power generation, transmission, and distribution, it was the culmination of a saga that began with a public release of proposed changes almost nine years ago. Agency rule changes send shockwaves of nervousness through the business sector it regulates. There are four sets of major OSHA changes in the new rules.
Compliance Date
New or Revised Rule
Standard…

Objective and measurable techniques to determine best safety practices on electrical systems.

Frequently asked questions
I hire qualified electricians, why do I need to monitor their every move?
You likely were diligent to hire technically competent electrical workers. Qualification ensures they can recognize and avoid injury from electrical hazards. It is the employer’s responsibility to train workers on specific facility hazards, ensure understanding, and monitor compliance after training has been given. These three steps must be effective, timely, and documented to keep workers safe and for you to comply with regulations and standards.
You won’t be monitoring their every move all the time. NFPA 70E establishes “periodic monitoring” as at least once a year. That may not be enough to satisfactorily know they will work…

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In this installment of What Works, a paper converting machine company improves access for local operators and distant engineers.

Paper Converting Machine (PCMC) in Green Bay, Wisconsin, builds machinery for a variety of industries including tissue converting and packaging, flexographic printing, and nonwovens. With three major production centers in the United States, the United Kingdom, and Italy, and with more than 1,000 team members worldwide, PCMC sells and services its machines installed at customers’ manufacturing facilities across the globe.
PCMC was using Phoenix Contact managed Ethernet switches and a wireless WLAN basic radio, but its existing remote connectivity solution was a proprietary system that had limited functionality. Previously, PCMC sold each customer a PC that had all the software required to diagnose and maintain the machinery, and PCMC…

The Internet of Things promises to allow equipment to communicate with other equipment and with control and monitoring systems that can interpret data and make decisions based on the analysis. Yes, the idea is for thinking machines to talk to each other. This is anything but your father’s manufacturing facility. Automated production, monitoring, alarming, and troubleshooting mean lower costs and better efficiencies. But machinery isn’t the only beneficiary of technological connectivity.
Mobile devices are changing everything. Managers, engineers, technicians, operators, and workers of every kind on the plant floor have never had greater access to more information than they do now. And that access will only continue to increase…

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Monitoring devices in new plants and retrofits need no wires and no batteries.

Wireless automation systems play a key role in reducing energy consumption. They can help to improve the carbon footprint of plants with a quick return on investment. World energy consumption will increase 56% by 2040, using 820 quadrillion Btu, but will already reach 639 quadrillion Btu by 2020, six years from now, according to U.S. Energy Information Administration, World energy demand and economic outlook, July 2013. This development is closely linked to CO2 emissions and global warming. In the past few years, areas in the United States have experienced high temperatures, wildfires, and droughts. These weather events could become more prevalent with the threat of climate change. As temperatures increase and as population grows, the…

In brief:
Ventilation openings help to maintain component temperatures inside the enclosure within certain design limits.
If these openings are blocked, either inadvertently or intentionally, overheating of the equipment may result.
A careful review of the standards and terminology is an excellent way to truly understand the various construction features used in electrical equipment enclosures and what exposure they create.
Electrical distribution equipment in all voltage classes often has ventilation openings to permit the circulation of air by convection within the enclosure. These ventilation openings help to maintain component temperatures inside the enclosure within certain design limits. If these openings are blocked, either…

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In this Big Picture Interview, John Martini explains what's new, what's now and what to consider before you invest.

John Martini is an assistant professor of electronics technology at the University of Arkansas - Fort Smith, where he teaches classes in the robotics certification program. His educational background includes an Associate of Applied Science in…

Robotics

In this installment of What Works, a cogeneration plant migrates it existing control system to a non-proprietary control system.

The Ripon Cogeneration Plant (Ripon Cogen) in Ripon, California, partnered with Maverick Technologies to perform a DCS migration of an existing proprietary Westinghouse WDPF BOP control system to a non-proprietary control system without any scheduled outage of the facility. A human-machine interface (HMI) for systems outside of the BOP was to be incorporated into the new control system.
The BOP control system is a complex and interdependent control system that involves all of the related areas within the overall Ripon Cogen vicinity including HRSG control, gas compressor, ammonia plant, chiller, and water treatment. This was an entirely brownfield project with all of the inherent problems and constraints: zero impact to production, limited…

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Training, cleanliness, and early results in a brewery’s implementation of a world-class process.

Figure 1. The OilSafe bulk system is the heart of the new lube room.
This is the third installment of a bi-monthly series about one plant’s continuing journey to implement a world-class lubrication process.
Beer Guy here with another update. It’s a busy time at the beer factory — peak season ended a few months ago, and now we’re focusing on things we can do better in the coming year. I haven’t had time to fill and leak-check all the tanks in the new lube room, but five of the eight are now filled and set up to recirculate for eight hours each (Figure 1). I’m also making slow-but-steady progress in other aspects of our lubrication process implementation. In my last article, I promised you updates on the training program and…

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Could new teaching techniques be the key to getting girls interested in STEM?

There must be 50 ways to start this story. I could say it’s bugged me that every salary survey I’ve ever covered about the control and automation field has shown that its gender-specific demographics are always about 98% male. Or I could once again echo the cry that everyone in the field is retiring, so it’s suffering an oozing brain drain, and where, oh where, are we going to get the next generation of engineers? Or I could report that, while doing some early research for this year’s two cover articles on science, technology, engineering and math (STEM) education, I’ve turned up some crucial news. Finally, I could just give thanks for getting unchained from my desk, and once again having the opportunity to go out and cover a…

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Young workers are eager to expand their skill set and want to see how the work they do affects their organization.

They're impatient. Needy. Demanding. As a generation, they expect more from their employers in terms of benefits and career advancement opportunities, and they expect it sooner.
Millennials have heard it all before. But the criticisms frequently…

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Cross-functional collaboration is vital, plant leaders say.

Interconnectedness was a dominant theme at this week's 19th annual ARC Industry Forum in Orlando, Fla. But the need for better connection within and across manufacturing plants isn't limited to the realm of the industrial Internet of things (IIoT), panelists repeatedly made clear.
For companies to be able to fully realize the cost savings and operational efficiencies made possible through smart technology, they need better collaboration across workforce teams.
Information technology and operational technology teams in particular too often don't have a good understanding of each other's demands and limitations, speakers said. "In a lot of organizations, there's a lot of tension between this manufacturing piece and this IT piece," offered…

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Aberdeen Group has published new research looking at how organizations are automating their recruiting process in order to improve the efficiency and effectiveness of their hiring initiatives.

Aberdeen Group has published new research looking at how organizations are automating their recruiting process in order to improve the efficiency and effectiveness of their hiring initiatives. This new study, Recruitment Technology: Quality Candidates and Quality Process, looks specifically at how organizations that have automated, either fully or in part, their recruiting function performed against those with fully manual processes. Those with a fully or partially automated process indicated that 73% of their new hires reached their first performance milestone on time, versus 67% of all others, while also reducing time to fill 3% over the previous year, and reducing cost to fill by 4%.
In addition to reaping the benefits of automation on…

How to create and sustain operational excellence

Align people, processes, and technology with your goals, and then measure.

In our most recent Manufacturing Operations Management (MOM) survey, more than 87% of companies reported instituting some type of OpEx (OpEx) or continuous improvement initiative. Unfortunately, it’s not uncommon for there to be difficulty in determining whether or not progress is being made toward those initiatives. So what’s one major thing standing between you and your OpEx targets? There’s a good chance it’s an effective metrics program.

Let’s examine what’s important in achieving a model of OpEx, as well as the role that an effective metrics program can play in making your goals a reality.

The reciprocal relationship between OpEx and metrics

OpEx and metrics programs have an interesting relationship. Without OpEx initiatives that establish the corporate culture and a common management system, it’s arguable that it would be very difficult to enable continuous improvement and that metrics wouldn’t get much attention.

On the other hand, without the ability to monitor and identify areas for improvement over time with metrics, it would be incredibly resource-consuming to determine if you were even moving toward the goals of your OpEx initiatives. The challenge is that setting business goals is much easier than actually executing on and achieving them, and metrics can help us to understand what’s working and what’s not, while we can still do something about it.

An OpEx framework to consider

Figure 1. Holistic OpEx aligns and optimizes people, processes, and technology with strategic objectives and is supported by a strong metrics program.

An holistic approach to OpEx aligns and then optimizes key resources — people, processes, and technology — with strategic objectives and is supported by a strong metrics program (Figure 1).

Strategic objectives typically focus on a combination of areas, including finance, operations, quality, manufacturing, energy management, and health and safety. However, as mentioned above, the challenge isn't in setting these objectives, it's in pursuing them by putting your resources into action. And optimizing your resources for this purpose takes a tactical, well-thought-out approach.

Let’s examine several important trends within each of these resource categories.

People: We may be moving toward a more automated manufacturing and industrial environment, but, without people at the wheel, all of the technology in the world would be useless. Strong leadership and executive support are critical for any OpEx initiative. It starts with the C-Suite executives — chief quality officer, chief operating officer, chief sustainability officer, and others — getting on board, and that mindset trickles down to the rest of the organization.

Processes: Disparate systems and business processes are slowly becoming a challenge of the past, and closed-loop/end-to-end business processes are the future. It’s imperative that you start to standardize processes globally where synergies exist, making them transparent, compliant, and collaborative across the value chain.

Technology: Whether it’s enterprise quality management software, manufacturing operations management software, enterprise resource planning, industrial energy management software, or another enterprise software solution, there’s a trend emerging whereby companies are beginning to deploy enterprise-wide systems. These deployments leverage a combination of standardized business processes in combination with today’s automation capabilities and software applications to manage the complexities of different manufacturing locations. The resulting communicative and collaborative capabilities are incomparable to the IT disconnect that many companies deal with today.

To optimize the impact of metrics, today’s most advanced companies are harmonizing people, processes, and technology, as well as intelligently streamlining processes, data, and content from across the value chain to the right people and in the right context. It’s often the more granular efforts by different teams across the value chain — working both collaboratively and independently — that amount to aggregate improvements toward strategic objectives.

Once you've achieved the right level of visibility with metrics, one of the most powerful characteristics of a strong metrics program is in its ability to enable continuous improvement. Specific goals for strategic objectives may be met, but in the long run you can always raise the mark for future performance. Without universal metrics visibility, this continuous improvement mentality would be a challenge to even conceive.

The right metrics for your organizations

The right set of metrics can be instrumental in monitoring how effectively those resources are being used and whether a particular resource or set of resources needs to be reallocated, ameliorated, or changed entirely. But it’s important to remember that every organization has its own set of challenges and corresponding strategic objectives. As a result, each will rely on different combinations of high-level metrics, as well as more industry-specific and job role-specific ones.

For instance, in manufacturing we can look across a number of categories, such as customer experience and responsiveness, quality, efficiency, inventory, compliance, maintenance, flexibility, innovation, costs, and profitability. The list may change when we focus on other business units or areas along the value chain, but the concept of OpEx and continually improving on what’s most important for the success of your business remains.

Finally, when building a metrics program it’s important not to confuse results with process performance. We need to have some metrics that report how we have performed in the past and another set of metrics that tell us how we’re are doing right now, as well as an understanding of how current process performance can be predictive of future results and what actions we can take now to improve future results.